Lewis Chainsaw Winch Manual

The Lewis Chainsaw Winch is a powerful, portable winching system designed to attach to most standard chainsaws, converting their rotational power into pulling force for logging, recovery, and lifting applications. It features a durable steel construction, adjustable mounting bracket, high-tensile steel cable with hook, and a gear reduction system for controlled pulling power. Below are key sections for safety, features, installation, operation, maintenance, and troubleshooting.

Features at a Glance

Key components: Winch Head Assembly, Mounting Bracket with Adjustable Clamps, Drive Adapter, Cable Drum with High-Tensile Steel Cable, Hook, Hand Crank for Manual Override, and Gear Housing.

Safety Warnings

Read all instructions before use. Failure to follow warnings can cause serious injury or death.

1. Personal Protective Equipment (PPE): Always wear gloves, eye protection, steel-toe boots, and chainsaw chaps when operating.
2. Inspection: Inspect winch, cable, hook, and chainsaw for damage before each use. Do not use if components are worn or damaged.
3. Load Limits: Do not exceed rated capacity (see Specifications). Overloading can cause cable failure or winch damage.
4. Anchor Points: Secure winch to a stable anchor (tree, vehicle, stump) using appropriate straps or chains. Ensure anchor can withstand load.
5. Clear Zone: Keep all persons at least 50 feet away from the cable path during operation. Cable under tension can snap and whip dangerously.
6. Chainsaw Operation: Operate chainsaw at recommended RPMs. Do not run chainsaw at full throttle for extended winching periods.

DANGER! Never stand in line with the cable. Never use a damaged cable or hook. Never leave tension on the cable when not actively winching.

Installation & Mounting

Ensure chainsaw is off and cool before installation.

1. Prepare Chainsaw: Remove guide bar and chain. Expose the clutch drum/sprocket.
2. Attach Drive Adapter: Slide the provided drive adapter onto the chainsaw's clutch drum. Secure with retaining clip or nut (if provided).
3. Mount Bracket: Position the mounting bracket on the chainsaw body, typically near the rear handle. Use adjustable clamps to secure it tightly. Ensure it does not interfere with controls or fuel tank.
4. Connect Winch Head: Mate the winch head's input shaft with the drive adapter. Secure the winch head to the mounting bracket using provided bolts.
5. Route Cable: Unspool the cable from the drum, ensuring no kinks. Attach the hook to your load anchor point.
6. Final Check: Verify all connections are tight. Ensure cable feeds smoothly onto the drum.

CAUTION! Do not modify the winch or mounting hardware. Use only provided parts.

Specifications

• Model: Lewis Winch Pro Series
• Rated Capacity: 2,000 lbs (single line pull)
• Cable: 50 ft of 3/16" galvanized aircraft cable
• Gear Ratio: 24:1 reduction
• Chainsaw Requirements: 50cc minimum engine size, standard clutch drum
• Weight: 15 lbs (winch only)
• Dimensions: 12" L x 8" W x 6" H
• Construction: Powder-coated steel housing, brass gears
• Warranty: 1-year limited warranty against defects

Controls and Operation

Primary Control: Chainsaw throttle controls winch speed and power.

Winch Controls: Quick-Release Lever (disengages gear for free spooling), Hand Crank Socket (for manual operation), Cable Drum Lock (prevents unwanted payout).

Operation Steps:

1. Secure anchor and load.
2. Disengage Quick-Release Lever to free-spool cable to desired length.
3. Re-engage lever to lock drum.
4. Attach hook to load.
5. Start chainsaw and apply gentle throttle to begin winching. Maintain steady pressure.
6. To stop, release throttle and apply chainsaw brake. Use Drum Lock if needed.
7. For manual retrieval, insert hand crank into socket and turn clockwise.

Tip: Winch in short bursts to prevent overheating the chainsaw clutch.

Winching Techniques

For logging, recovery, and general pulling.

1. Straight Pull: Align winch, cable, and load in a straight line for maximum efficiency.
2. Double-Lining (Pulley Block): Use a snatch block to double pulling power and change direction. Reduces strain on winch.
3. Bridging: Use a tree saver strap around a tree as an anchor point to avoid damage.
4. Choker Setting: Wrap cable around log and hook back onto itself for a secure grip.
5. Recovery: For vehicle recovery, attach to frame or tow point—never to bumpers or axles.
6. Lifting: For light lifting, ensure load is balanced and path is clear. Do not lift over people.

WARNING! Always have an escape path. If winching a vehicle, stay inside the vehicle if possible. Never hook cable back onto itself without a proper choker setting.

Maintenance & Inspection

Perform after each use and before storage.

1. Cable Inspection: Check for frayed wires, kinks, or rust. Replace if more than 3 broken wires are found in any section.
2. Hook Inspection: Check for cracks, deformation, or worn latch. Replace if damaged.
3. Gearbox Lubrication: Apply grease via zerk fittings every 10 hours of operation. Use high-temperature lithium grease.
4. Mounting Hardware: Check all bolts and clamps for tightness.
5. Clean: Wipe down with a dry cloth. Remove dirt and sawdust from gears and cable.
6. Function Test: Operate winch without load to ensure smooth operation.

CAUTION! Do not lubricate the cable. Keep grease away from cable drum braking surfaces.

Storage

Store in a dry, cool place. Apply a light coat of oil to metal surfaces to prevent rust.

1. Retract cable fully onto drum.
2. Engage Drum Lock to prevent unspooling.
3. Clean all components.
4. Place in carrying case or hang on wall bracket.
5. Store separately from chainsaw to avoid corrosion from bar oil or fuel.

Tip: Hang cable hook on a designated spot on the drum to keep it from tangling.

Warranty Information

Lewis Tools provides a 1-year limited warranty from date of purchase against defects in materials and workmanship under normal use. Warranty does not cover damage from misuse, overload, improper installation, lack of maintenance, or wear items (cable, hook). For warranty service, contact Lewis Tools Customer Service at 1-800-555-WINCH or visit www.lewistools.com/support with proof of purchase.

Troubleshooting

Service: For repairs not covered here, contact authorized Lewis service center. Do not attempt to disassemble gear housing.

Support: 1-800-555-WINCH; www.lewistools.com